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Publication numberUS20040133205 A1
Publication typeApplication
Application numberUS 10/632,760
Publication dateJul 8, 2004
Filing dateAug 1, 2003
Priority dateJun 24, 2002
Also published asEP1653872A1, EP1653872A4, EP1653872B1, EP2594213A1, US7077843, US8652181, US8778001, US20060293672, US20070016206, US20070233120, WO2005011508A1
Publication number10632760, 632760, US 2004/0133205 A1, US 2004/133205 A1, US 20040133205 A1, US 20040133205A1, US 2004133205 A1, US 2004133205A1, US-A1-20040133205, US-A1-2004133205, US2004/0133205A1, US2004/133205A1, US20040133205 A1, US20040133205A1, US2004133205 A1, US2004133205A1
InventorsJeffrey Thramann, Michael Fulton, Bryan Hildebrand, Charles Powell
Original AssigneeJeffrey Thramann, Michael Fulton, Bryan Hildebrand, Powell Charles B.
Export CitationBiBTeX, EndNote, RefMan
External Links: USPTO, USPTO Assignment, Espacenet
Cervical plate
US 20040133205 A1
Abstract
The present invention provides a cervical plate and bone graft(s) that are capable of being attached prior to insertion of the bone graft into an intervertebral space. After insertion, the vertebrae hold the bone graft and cervical plate in place facilitating the anchoring of the cervical plate to the vertebrae. Further, a screw back out prevention device can be coupled to the cervical plate to prevent screws from backing out.
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Claims(49)
We claim:
1. An apparatus useful in placing bone grafts in a spine of a patient, comprising:
a cervical plate;
the cervical plate having a top side and a bottom side;
at least one attachment mechanism;
the at least one attachment mechanism coupled to the bottom side of the cervical plate; and
the attachment mechanism for coupling at least a first bone graft to the cervical plate prior to insertion of the first bone graft into an intervertebral space,
wherein prior to attaching the cervical plate to at least one vertebrae, the cervical plate is held in place by adjacent vertebrae squeezing the first bone graft.
2. The cervical plate according to claim 1, wherein the at least one attachment mechanism comprises at least one protrusion.
3. The cervical plate according to claim 1, wherein the attachment mechanism is fusion of at least one bone graft to the cervical plate to form one integrated unit.
4. The cervical plate according to claim 1, wherein the at least one attachment mechanism comprises at least one detent adapted to receive at least one corresponding protrusion.
5. The cervical plate according to claim 1, wherein the at least one attachment mechanism comprises at least one of a screw, an adhesive, a nail, and a plurality of prongs.
6. The cervical plate according to claim 1, wherein the cervical plate comprises biocompatible material.
7. The cervical plate according to claim 6, wherein the biocompatible material is bio absorbable material.
8. A cervical plate with a screw back out prevention device, comprising:
a cervical plate;
the cervical plate having at least one screw hole through which at least one screw extends to anchor the cervical plate to a vertebra;
the cervical plate having at least one channel with at least one engaging edge;
a cover plate having at least one plate edge, the at least one plate edge extends over a portion of a screw head of the at least one screw;
the cover plate having a locking extension with at least one locking edge at a distal end of the locking extension, wherein the cervical plate is attached to the vertebra using the at least one screw and the locking extension is inserted into the channel such that the at least one engaging edge and the at least one locking edge engage and hold the cover plate such that the at least one plate edge of the cover plate is substantially adjacent the portion of the screw head of the at least one screw to prevent the at least one screw from backing out.
9. The cervical plate according to claim 8, wherein the cover plate comprises a shape, the shape comprising at least one of a polygonal shape, a circular shape, an elliptical shape, a letter shape, a linear shape, an arc shape, a zigzag shape, a convex shape, and a concave shape.
10. The cervical plate according to claim 8, wherein the at least one engaging edge is a lip and the at least one locking edge is a shoulder.
11. The cervical plate according to claim 8, wherein
the locking extension comprises a plurality of prongs coupled to the cover plate and extending from the cover plate in an inverted V shape, each of the plurality of prongs having the at least one locking edge at the distal end; and
the cover plate comprises at least one access port,
such that a tool can be inserted through the at least one access port to squeeze the plurality of prongs together to allow the locking edge of each of the plurality of prongs to fit into the at least one channel,
wherein when the tool is removed, the prongs separate and the at least one locking edge engages the at least one engaging edge.
12. The cervical plate according to claim 8, wherein the locking extension comprises,
a plurality of prongs coupled to the cover plate and extending from the cover plate in an inverted V shape, each of the plurality of prongs having the at least one locking edge at the distal end, the at least one locking edge having a wedge shaped extension, such that while inserting the locking extension into the channel, the at least one engaging edge and the wedge shaped extensions cause the prongs to squeeze together wherein prongs separate when the wedge shaped extension moves beyond the at least one engaging edge causing the plurality of prongs to move apart such that the at least one locking edge engages the at least one engaging edge.
13. The cervical plate according to claim 8, wherein the at least one engaging edge is formed from at least one hollow in the channel.
14. The cervical plate according to claim 13, wherein the at least one locking edge is a protrusion formed on the locking extension.
15. The cervical plate according to claim 14, wherein the protrusion is an elastically-loaded pin.
16. The cervical plate according to claim 8, wherein the at least one engaging edge is a protrusion in the channel.
17. The cervical plate according to claim 16, wherein the at least one locking edge is a hollow formed on the locking extension.
18. A cervical plate with a screw back out prevention device, comprising:
a cervical plate;
the cervical plate having at least one screw hole through which at least one screw can be threaded to anchor the cervical plate to a vertebra;
at least one locking bar slidably coupled to the cervical plate;
the at least one locking bar having a locking edge, the at least one locking bar having at least a first position and at least a second position, in the first position the locking edge does not engage a screw head of the at least one screw and in the second position the locking edge engages the screw head of the at least one screw; and
at least one locking stud coupled to the at least one locking bar to secure the at least one locking bar in the second position, such that
when the at least one locking bar is in the first position, the at least one screw can be unthreaded and when the at least one locking bar is in the second position, the at least one screw is inhibited from unthreading by the at least one locking bar.
19. The cervical plate according to claim 18, wherein at least one locking stud comprises at least one of a screw, a nail, a pin, a cam, and a bolt.
20. The cervical plate according to claim 18, wherein the at least one locking bar extends a length of the cervical plate.
21. A screw back out prevention device for use with cervical plates to inhibit bone screws from backing out, the prevention device comprising:
a bushing;
the bushing having an inner edge forming a gap through which a screw can be threaded;
at least one elastically-loaded pin;
the bushing resides between the head of the screw and the cervical plate such that the at least one elastically-loaded pin engages the screw when the screw is threaded to inhibit the screw from backing out.
22. The screw back out prevention device according to claim 21, wherein the elastically-loaded pin engages at least one thread of the screw.
23. The screw back out prevention device according to claim 21, wherein the elastically-loaded pin engages at least one notch in the screw.
24. The screw back out prevention device according to claim 23, wherein the at least one notch is located in a head of the screw.
25. The screw back out prevention device according to claim 21, wherein the at least one elastically-loaded pin comprises a plurality of elastically-loaded pins.
26. The screw back out prevention device according to claim 21, further comprising at least one channel in the bushing corresponding to the at least one elastically-loaded pin, wherein a portion of the elastically-loaded pin resides in the at least one channel.
27. The screw back out prevention device according to claim 26, further comprising at least one spring between the busing and the at least one elastically-loaded pin.
28. The screw back out prevention device according to claim 27, wherein the at least one spring comprises a helical spring.
29. The screw back out prevention device according to claim 27, wherein the elastically-loaded pin has elastic movement caused by at least one of pneumatics, magnetics, and shaped memory alloys.
30. A back out prevention device for a cervical plate, the prevention device comprising:
a bushing;
a screw; and
at least one bonding material, wherein
the bushing having an inner sidewall, the at least one bonding material residing on at least one portion of the inner sidewall, wherein
the screw comprises a screw head and a shank, wherein
the screw head having an outer sidewall, the at least one bonding material residing on at least one portion of the outer sidewall, wherein
when the screw is threaded into a vertebral body, the at least one bonding material on the at least one portion of the inner sidewall substantially aligns with the at least one bonding material on the at least one portion of the outer sidewall forming a bond that inhibits the screw from backing out.
31. The screw back out prevention device according to claim 30, wherein the bonding material is a self-bonding material.
32. The screw back out prevention device according to claim 30, wherein the bonding material is at least one of a thermally activated bonding material, pressure activated bonding material, an electrically activated bonding material, and a radiation activated bonding material.
33. The screw back out prevention device according to claim 30, wherein the bonding material is at least one of an epoxy, an acrylics, a resin, a silicone, an adhesive, a glue, and a tape.
34. The screw back out prevention device according to claim 31, wherein the at least one self bonding material is in a form of a washer and the at least one self bonding material resides in a first notch on the inner sidewall and a second notch on the outer sidewall.
35. The screw back out prevention device according to claim 31, wherein the at least one self bonding material is coated on the inner sidewall and the outer sidewall.
36. A back out prevention device for a cervical plate, the prevention device comprising:
a screw hole in a cervical plate;
a screw; and
at least one bonding material, wherein
the screw hole having an inner sidewall, the at least one bonding material residing on at least one portion of the inner sidewall, wherein
the screw comprises a screw head and a shank, wherein
the screw head having an outer sidewall, the at least one bonding material residing on at least one portion of the outer sidewall, wherein
when the screw is threaded into a vertebral body, the at least one bonding material on the at least one portion of the inner sidewall substantially aligns with the at least one bonding material on the at least one portion of the outer sidewall forming a bond that inhibits the screw from backing out.
37. The screw back out prevention device according to claim 36, wherein the bonding material is a self-bonding material.
38. The screw back out prevention device according to claim 36, wherein the bonding material is a thermally activated bonding material, a pressure activated bonding material, an electrically activated bonding material, and a radiation activated bonding material.
39. The screw back out prevention device according to claim 36, wherein the bonding material is at least one of an epoxy, an acrylic, a resin, a silicone, an adhesive, a glue, and a tape.
40. The screw back out prevention device according to claim 37, wherein the at least one self bonding material is in a form of a washer and the at least one self bonding material resides in a first notch on the inner sidewall and a second notch on the outer sidewall.
41. The screw back out prevention device according to claim 37, wherein the at least one self bonding material is coated on the inner sidewall and the outer sidewall.
42. A cervical plate having a screw back out prevention device, comprising:
a cervical plate;
at least one ridge coupled to a surface of the cervical plate;
at least one cover; and
the at least one cover having at least one groove corresponding to the at least one ridge and at least one peripheral edge, such that
when installed the at least one groove and at least one ridge form a fitting and the at least one peripheral edge extends over at least one screw head to inhibit back out.
43. The cervical plate according to claim 42, wherein the cover plate comprises a shape, the shape comprising at least one of a polygonal shape, a circular shape, an elliptical shape, a letter shape, a linear shape, an arc shape, a zigzag shape, a convex shape, and a concave shape.
44. The cervical plate according to claim 42, wherein the at least one ridge has at least one lip and the at least one groove has at least one corresponding shoulder such that the at least one lip and the at least one shoulder abut form a snap lock fitting.
45. A cervical plate with a screw back out prevention device, comprising:
a cervical plate;
at least one screw hole in the cervical plate through which at least one screw is threaded to anchor the cervical plate to a vertebra; and
means for inhibiting the backing out of the at least one screw.
46. The cervical plate according to claim 45, wherein the means for inhibiting comprises:
at least one channel in a surface of the cervical plate;
at least one cover plate having an edge that extends over the at least one screw; and
at least one locking extension coupled to the at least one cover plate, wherein
the at least one locking extension comprises at least one prong that extends from the at least one cover plate into the at least one channel forming forms a fitting with the at least one channel.
47. The cervical plate according to claim 45, wherein the means for inhibiting comprises:
at least one movable bar having a first position allowing the at least one screw to be threaded and a second position inhibiting the at least one screw from being threaded;
the movable bar slidably coupled to the cervical plate; and
a locking device comprising at least one of a pin, a screw, a bolt, a magnet, a cam, and a clip connected to the cervical plate and the at least one movable bar locking the at least one movable bar in the second position.
48. The cervical plate according to claim 45, wherein the means for inhibiting comprises:
at least one bushing formed to be threaded on the at least one screw; and
an elastically-loaded locking pin coupled to the bushing and extending radially inward, wherein the locking pin has a frictional engagement with the at least one screw inhibiting the at least one screw from backing out.
49. The cervical plate according to claim 45, wherein the means for inhibiting comprises a bonding material.
Description
RELATED APPLICATIONS

[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 10/178,371, filed Jun. 24, 2002, titled CERVICAL PLATE, now U.S. Pat. No. 6,062,257. This application also is related to U.S. patent application Ser. No. 10/178,656, filed Jun. 24, 2002, titled IMPACTOR FOR USE WITH CERVICAL PLATE.

FIELD OF THE INVENTION

[0002] The present invention relates to apparatuses and methods for treating and correcting spinal abnormalities and, more particularly, to cervical plates and artificial discs useful in procedures relating to correction of abnormalities in the spine

BACKGROUND OF THE INVENTION

[0003] The vertebrae of the human spine are arranged in a column with one vertebra on top of the next. Between each vertebra exists an intervertebral disc that transmits force between adjacent vertebrae and provides a cushion between the adjacent vertebrae.

[0004] Sometimes, back pain is caused by degeneration or other deformity of the intervertebral disc (“diseased disc”). Conventionally, surgeons treat diseased discs by surgically removing the diseased disc and inserting a bone graft in the space vacated by the diseased disc. The adjacent vertebrae are then immobilized relative to one another. Eventually, the vertebrae grow into one solid piece of bone.

[0005] Currently, it is difficult to insert the bone graft into the vacated space and fuse the adjacent vertebrae. The current process of inserting a bone graft and fusing the adjacent vertebrae will be explained with referring to FIGS. 1 and 2. FIG. 1 shows two adjacent vertebrae 102 and 104. Located between vertebrae 102 and 104 is an intervertebral space 106 partially filled by a bone graft 108. When the bone graft 108 is first inserted into the intervertebral space 106, the adjacent vertebrae 102 and 104 are manually kept apart by the surgeon using, for example, a retracting device (not shown). As shown in FIG. 2, once the bone graft 108 is placed, the surgeon releases the adjacent vertebrae 102 and 104 allowing them to squeeze the bone graft 108 and hold the bone graft 108 in place.

[0006] To immobilize the vertebrae 102 and 104 with the bone graft 108 in place, the surgeon next applies a cervical plate 202 over the adjacent vertebrae 102 and 104. Cervical plate 202 may have a central viewing window 204 and one or more screw holes 206, in this example four screw holes 206 a-206 d are shown. Four bone screws (which will be identified by reference numerals 208 a-208 d) would be screwed into the vertebrae using the screw holes 206 to anchor the cervical plate to the vertebrae and immobilize the vertebrae with respect to one another.

[0007] As can be appreciated, attaching the cervical plate 202 using the bone screws 208 is a difficult endeavor. Generally, a temporary screw (not shown) is placed in one of the screw holes, for example 206 a. Bone screw 208 c would then be partially screwed into the bone at screw hole 206 c. The temporary screw in hole 206 a would be replaced by bone screw 208 a, which would be tightened. Then the other bone screws 208 would be screwed into the bone in a cross point manner. The ability of the cervical plate to move freely in relation to the vertebrae 102 and 104 and the bone graft 108 until the bone screws anchor the plate causes difficult in attaching the cervical plate. This is made more difficult because, generally, only a portion of the cervical plate is visible to the surgeon at any given moment (due to space constraints and surgical tools).

[0008] While the above example relates to replacement of one intervertebral disc between two adjacent vertebrae, sometime it is necessary to replace two or more discs spanning three or more vertebrae. The problems associated with replacing one disc become more exacerbated the more discs and vertebrae that our involved.

[0009] Due to the small margins for error in placing the bone screws into the vertebrae, it would be desirous to develop a cervical plate that was not as free to move prior to attachment with the bone screws.

SUMMARY OF THE INVENTION

[0010] To attain the advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, apparatuses to facilitate the insertion of a bone graft into an intervertebral space and positioning of a cervical plate are provided. In particular, a cervical plate having an attachment mechanism that attaches the bone graft to the cervical plate prior to the cervical plate being inserted into the intervertebral space. The vertebra would hold the graft and the cervical plate in position to facilitate the anchoring of the cervical plate to vertebrae.

[0011] The present invention further provides screw back out prevention mechanisms to prevent the bone screws anchoring the cervical plate from backing out.

[0012] The foregoing and other features, utilities and advantages of the invention will be apparent from the following more particular description of a preferred embodiment of the invention as illustrated in the accompanying drawings. Further, the advantages and purpose of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims.

BRIEF DESCRIPTION OF THE DRAWING

[0013] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present invention, and together with the description, serve to explain the principles thereof. Like items in the drawings are referred to using the same numerical reference.

[0014]FIG. 1 shows adjacent vertebrae with a bone graft;

[0015]FIG. 2 shows adjacent vertebrae with a bone graft and cervical plate;

[0016]FIG. 3 shows adjacent vertebrae with a bone graft and cervical plate having an attachment mechanism illustrative of the present invention;

[0017]FIG. 4 shows a cross-section of the bone graft and cervical plate of FIG. 3;

[0018]FIG. 5 shows an alternative attachment mechanism illustrative of the present invention;

[0019]FIG. 6 is a flowchart 600 illustrating use of the present invention;

[0020]FIG. 7; shows an impactor illustrative of the present invention;

[0021]FIG. 8 shows the impactor of FIG. 7 with a cervical plate illustrative of the present invention;

[0022]FIG. 9 is a flowchart illustrative of a use of the impactor consistent with the present invention;

[0023]FIGS. 10A and 10B show an embodiment of a screw back out prevention device consistent with the present invention;

[0024]FIG. 11 shows another embodiment of a screw back out prevention device consistent with the present invention;

[0025]FIG. 12 shows another embodiment of a screw back out prevention device consistent with the present invention;

[0026]FIG. 13 shows still another embodiment of a screw back out prevention device consistent with the present invention; and

[0027]FIG. 14 shows still another embodiment of a screw back out prevention device consistent with the present invention.

DETAILED DESCRIPTION

[0028] Some embodiments of the present invention are described with reference to FIGS. 3 to 14. In particular, FIGS. 3 and 4 show a cervical plate 300 and bone graft 302. Cervical plate 300 has a viewing window 304, screw holes 306, and an attachment mechanism 400 (shown in phantom in FIG. 3). As best seen in FIG. 4, cervical plate 300 has attachment mechanism 400 attaching the bone graft 302 to the cervical plate 300. While cervical plate 300 could be made of numerous biocompatible materials, it is believed cervical plate 300 should be made of bio absorbable material. Bio absorbable or resorbable devises are generally known in the art, see for example, U.S. Pat. No. 6,241,771, titled RESORBABLE INTERBODY SPINAL FUSION DEVICES, issued to Gresser et al., on Jun. 5, 2001, incorporated herein by reference.

[0029] Attachment mechanism 400 can be any of a number of different attachment mechanisms. For example, as shown in FIG. 4, attachment mechanism 400 comprises a pin or stud attached to the cervical plate inserted into a hole or detent in the bone graft 302. Alternatively, attachment mechanism 400 could be a spike inserted into bone graft 302 without bone graft 302 having a corresponding hole or detent to receive the spike, similar to a thumb tack. Alternatively, attachment mechanism 400 could comprise a pin or stud attached to the bone graft 302 inserted into a hole or detent in cervical plate 300. Also, attachment mechanism 400 could be any style snap lock or friction fitting, such as the cavity formed in FIG. 5 between protrusions 504, explained in more detail below. It would be possible to provide barbs and/or lips on attachment mechanism 400 to facilitate the connection. Moreover, while two attachment mechanisms 400 are shown, more or less attachment mechanisms could be used. Further, attachment mechanism 400 could be an adhesive layer between the cervical plate 300 and bone graft 302. Still further, attachment mechanism 400 could be a screw device so that bone graft 302 and cervical plate 300 are attached using a screw mechanism. Finally, the cervical plates 300 could be made as a single integral unit with the bone graft 302, although that would be difficult due to the numerous sizes and shapes of bone grafts and plates necessary to perform the surgery.

[0030]FIG. 5 shows cervical plate 500 attached to a bone graft 502 by prongs 504 on bone graft 502. As shown, prongs 504 attached to the bone graft grasp cervical plate 500 forming a frictional engagement. Alternatively, but not shown, cervical plate 500 could have prongs that grasp bone graft 502.

[0031] As one of ordinary skill in the art would recognize on reading this disclosure, the number of ways the bone grafts could be attached to the cervical plate is numerous. To the extent alternative attachment means are not expressly identify above, this description should not be limited to the embodiments identified and described above. Rather, the specific embodiments identified are for illustrative purposes.

[0032]FIG. 6 is a flowchart 600 illustrating a method of using the present invention. In particular, the surgeon fits a bone graft into the intervertebral space, step 602. Then, with the bone graft in place and the adjacent discs holing the bone graft in place, the surgeon sizes a cervical plate, step 604. Once the cervical plate and bone graft are sized, the surgeon removes the plate and graft from the patient, and attaches the bone graft to the cervical plate, step 606. Next, the combination bone graft and plate device is placed in the intervertebral space such that the adjacent discs hold the bone graft and plate in place, step 608. The cervical plate is then anchored to the adjacent vertebral bodies, step 610. Because surgeon attached the cervical plate to the bone graft, and the adjacent vertebrae hold the bone graft in place, the cervical plate remains fixed in place while the surgeon anchors the plate to the vertebrae.

[0033] As one of ordinary skill in the art would recognize on reading the above disclosure, the same general device and procedure is used when inserting multiple bone grafts. For example, if fusing four vertebrae, a surgeon would need to place three bone grafts. Conventionally, the three bone grafts are sized and placed in the intervertebral space and a cervical plate is sized for the three grafts. Using the present invention, the three bone grafts could all be removed and attached to the cervical plate and then refitted into the patient. However, it is believed attaching multiple bone grafts to the cervical plate would make it difficult to fit the device into the patient. It is believed to be more efficient to insert bone grafts and size the bone grafts and cervical plate, then remove one of the bone grafts while leaving other bone grafts in the spine. The removed bone graft would be attached to the plate. The one bone graft with the cervical plate attached is refitted into the patient and screws can be used to anchor the entire device with the one bone graft providing the stability for the cervical plate.

[0034] As mentioned above, inserting the bone graft and cervical plate includes using a retracting device to hold the adjacent discs apart, inserting the bone grafts and sizing the cervical plate, removing cervical plate and the retracting device, allowing the adjacent discs to squeeze the bone graft, then replacing and anchoring the cervical plate. A difficulty arises using the present invention because the retracting devices need to be removed prior to placing and anchoring the cervical plate. Thus, when the bone graft is removed and attached to the cervical plate, the retracting devices need to be removed prior to replacing the combined bone graft and cervical plate. However, on removing the retracting devices, the adjacent discs move together making it difficult to insert the bone graft between the adjacent discs.

[0035]FIG. 7 shows an impactor 700 capable of opening the space between the discs to ease the insertion of the bone graft attached to the cervical plate. Impactor 700 has a handle 702, a cervical plate holder 704, and prongs 706 forming cavity 708. Impactor 702 could have various numbers of prongs, but it is believed two prongs work well. Cervical plate holder 704 is designed to hold the cervical plate such that the prongs 706 extend downward beyond the cervical plate and bone graft attachment. Prongs 706 could be spaced to form cavity 708 such that placing the cervical plate in the cavity 708 would form a friction fitting releasably coupling the cervical plate to the impactor 700. The prongs 706 would act as a wedge to separate the adjacent discs allowing placement of the bone graft in the intervertebral space. Once the bone graft is placed, the impactor 700 would be completely removed from the patient. Thus, the cervical plate and impactor would be releasably coupled prior to insertion. FIG. 8 shows a top side elevation view of the impactor 700 holding a cervical plate 802. Cervical plate 802 is shown without a viewing window, but one could be used if desired.

[0036]FIG. 9 is a flowchart 900 illustrating using the impactor 700 with the cervical plate 802. For convenience, flowchart 900 is described for insertion of a single bone graft. One of skill in the art will recognize on reading the disclosure, however, that the device and procedure would be usable with insertion of multiple bone grafts. Initially, the surgeon fits a bone graft into the intervertebral space, step 902. Then, with the bone graft in place and the adjacent discs holing the bone graft in place, the surgeon sizes a cervical plate, step 904. Once the cervical plate and bone graft are sized, the surgeon removes the plate and graft from the patient, and attaches the bone graft and the cervical plate, step 906. Next, the impactor is releasably attached to the cervical plate, step 908. The impactor with the cervical plate and bone graft is used to separate the adjacent vertebrae, step 910. With the impactor holding the adjacent vertebrae apart, the bone graft is inserted in the intervertebral space such that the cervical plate is placed to be anchored to the adjacent vertebrae, step 912. The impactor is removed allowing the adjacent vertebrae to hold the bone graft and cervical plate in place, step 914. Finally, the cervical plate is anchored to the vertebrae, step 916.

[0037] Once surgically placed and anchored, cervical plate bone screws have a tendency to become loose, which is commonly referred to as backing out. Many devices have been devised to inhibit bone screws from backing out; however, none are particularly satisfactory.

[0038] Referring now to FIGS. 10A and 10B, a cervical plate 1000 with a back out prevention device 1002 in accordance with one embodiment of the present invention is shown. While the respective vertebrae have not been specifically shown in FIGS. 10A and 10B, cervical plate 1000 has been surgically implanted, and bone screws 1004 have been threaded into vertebral bodies through screw holes 1006 in plate 1000. A surface 1008 of plate 1000 contains at least one channel 1010 or groove. Back out prevention device 1002 comprises a cover 1012 and locking extension 1014 (best seen in FIG. 10B). Cover 1012 is sufficiently large to allow at least one perimeter edge 1016 of cover 1012 to extend over a head 1018 of screw 1004. When installed, edge 1016 is substantially aligned with head 1018 and prevents backing out of screw 1004. Locking extension 1014 comprises one or more elastic prongs 1020, for example biocompatible plastic or spring metal. Prongs 1020 fit into channel 1010 to hold back out prevention device 1002 in place. To facilitate placement of prongs 1020 into channel 1010, cover 1012 may have at least one access port 1022 through which a tool (not specifically shown) can be inserted. The tool would flex prong 1020 such that prong 1020 easily fits into channel 1010. When the tool is removed, prong 1020 would tend to return to its original position and apply a frictional force to seat back out prevention device.

[0039] As shown by FIG. 10B, one embodiment of back out prevention device 1002 comprises cover 1012 with multiple prongs 1020 forming an inverted V shape. Prongs 1020 have a distal end 1024 with a locking edge 1026. In this case, locking edge 1026 comprises a shoulder or protrusion. As shown in FIG. 10B, locking edge 1026 could have a wedge shape to facilitate insertion of prongs 1020 into channel 1010. In this case, use of the tool and access port 1022 may be unnecessary. Correspondingly, channel 1010 includes an engaging edge 1028. In this case, engaging edge 1028 comprises a lip or undercut. Of course, locking edge 1026 could comprise a hollow and engaging edge 1028 could comprise a corresponding protrusion, etc. Similarly, surface 1008 could have a raised extension with protrusions and cover 1012 could have a channel with a lip or shoulder. The channel of cover 1012 would be aligned with raised extensions on surface 1008 forming a fitting, such as a snap lock or a frictional engagement.

[0040] While shown as a square or rectangular shape, cover 1012 can be formed of many shapes and/or configurations. For example, cover 1012 could be elliptical, circular, some other polygon, linear, an arc or curve, convex or concave, irregular, a zig-zag, a letter shape, or the like. Further, as shown head 1018 resides above plate 1000 and cover plate 1012 resides above head 1018; however, one of skill in the art would recognize on reading the disclosure, that head 1018 and cover plate 1012 could be countersunk such that the head 1018 and cover plate 1012 reside substantially in the same plane as plate 1000.

[0041] Referring now to FIG. 11, another cervical plate 1100 with two back out prevention devices 1102 d and 1102 u is shown. Prevention device 1102 d is shown deployed and prevention device 1102 u is shown undeployed. Plate 1100 would be surgically implanted and bone screws 1104 threaded into the vertebral body through screw holes 1106.

[0042] Prevention devices 1102 comprise a plurality of bars 1108 having a deployed state (shown by prevention device 1102 d) and an undeployed state (shown by prevention device 1102 u). In the deployed state, prevention device 1102 d has a peripheral edge 1110 on bars 1108 that extend over a head 1112 of screws 1104. In the undeployed state, prevention device 1102 u has bars 1108 relatively closer to each other where peripheral edge 1110 does not extend over head 1112, which makes screws 1104 freely movable. When deployed, a locking device 1114, such as a pin, stud, screw, clip, cam, or the like is inserted or rotated between bars 1108 to lock prevention device 1102 d in the deployed state. For example, after bars 1108 are deployed, a screw could be inserted to maintain the separation. Alternatively, a cam could be rotated to maintain separation. Locking device 1114 would be removed to undeploy the prevention device. While prevention device 1102 is shown sized similar to a single screw head, prevention device 1102 could have bars 1108 that extend the length of the cervical plate so only one prevention device is necessary for multiple sets of screws.

[0043]FIG. 12 shows a top plan view of another back out prevention device 1200 consistent with the present invention. Unlike prevention devices 1000 and 1100, which generally prevent screws from backing out by engaging a screw head, prevention device 1200 engages, for example, a thread of a screw or a notch located, for example, in the screw head. Back out prevention device 1200 includes a bushing 1202 and at least one locking pin 1204, in which three pins 1204 are shown in this case. Bushing 1202 forms a ring or thread through which a screw (not specifically shown) can be threaded. A spring 1206 or other elastic device pushes locking pin 1204 radially inward such that pins 1204 provide sufficient force on at least one thread or notch of the bone screws (not specifically shown in FIG. 12). Spring 1206 should not be construed as a conventional helical spring, but could be a number of elastic devices including, for example, elastic plastics, air loaded dampers, magnetics, shaped memory alloys, or the like. Thus, spring or spring loaded should be used generically to mean a device with elastic movement ability. Basically, spring 1206 needs to provide sufficient outward force to seat pin 1204 against a thread, notch, or surface of the screw or screw head, but be sufficiently resilient to allow the screw to be threaded into bone. (Notice, spring 1206 and pin 1204 could be combined into a single unit using). Spring 1206 could be flush between the pin 1204 and bushing or, as shown, spring 1206 could reside in a channel 1208 in bushing 1202.

[0044]FIGS. 13 and 14 show cross-sectional views of screw back out prevention device 1300 and 1400, respectively. FIG. 13 shows a portion of a cervical plate 1302 about a screw hole 1304. Residing in screw hole 1304 would be a bushing 1306 that contains a notch 1308, groove, or channel. A screw would be threaded into vertebral bodies (not specifically shown in FIG. 13) through screw hole 1304 such that screw head 1310 resides as shown. Screw head 1310 has a notch 1312, groove, or channel, corresponding to notch 1308. Residing in notch 1308 and notch 1312 is a self-bonding material 1314, such as high molecular weight polyethylene, nylons, and biopolymers and other self-bonding material commonly used in the aeronautical and automotive industries. Instead of self-bonding material 1314, material 1314 could be replaced with heat fusible material, pressure sensitive material, radiation curing, or other adhesives that require activation to adhere. Self-bonding material 1314 provides back out prevention because when the screw is threaded into the vertebral bodies bonding material 1314 in notch 1308 engages bonding material 1314 in notch 1312 and bonds. Thus, screw head 1310 is held in place. Although shown in a notch, material 1314 could be layered, such as by a coating or spray, on bushing 1306 and screw head 1310.

[0045] Similarly, FIG. 14 shows a portion of a cervical plate 1402 about a screw hole 1404. Residing in screw hole 1404 is a screw head 1406. Screw hole 1404 has sidewalls 1408. Residing on sidewalls 1408 exists at least one strip of self-bonding material 1410. In this case, for example, self-bonding material 1410 is a spray on type of material. Screw head 1406 has exterior sidewalls 1412. Residing on sidewalls 1412 exists at least one strip of self-bonding material 1410 corresponding to the strip of self-bonding material 1410 on sidewalls 1408. Again, instead of a spray or coating, material 1410 could reside in a notch on sidewall 1408 and sidewall 1412.

[0046] Alternatively to a self-bonding material, other materials may be used. For example material 1410 (or 1314) may be a type of heat fusion plastic. To use heat fusion, once the screw is threaded and the materials align, a heat activation signal would be applied to fuse the materials. Other bonding materials, such as epoxies, acrylics (such cyanoacrylates and anaerobics), silicones, pastes, tapes, and glues, and the like could be used for bonding material 1410 (or 1314), but would inhibit threading of the screw as well as be useful as a screw back out prevention device.

[0047] While the invention has been particularly shown and described with reference to some embodiment thereof, it will be understood by those skilled in the art that various other changes in the form and details may be made without departing from the spirit and scope of the invention.

Referenced by
Citing PatentFiling datePublication dateApplicantTitle
US7048739Dec 31, 2002May 23, 2006Depuy Spine, Inc.Bone plate and resilient screw system allowing bi-directional assembly
US7175624Dec 31, 2002Feb 13, 2007Depuy Spine, Inc.Bone plate and screw system allowing bi-directional assembly
US7256745Dec 29, 2004Aug 14, 2007Mitsumi Electric Co., Ltd.Fixing device for fixing an object to a fixing plate and antenna apparatus using the fixing device
US7651517Apr 13, 2006Jan 26, 2010Depuy Acromed, Inc.Bone plate and resilient screw system allowing bi-directional assembly
US7931678Dec 8, 2004Apr 26, 2011Depuy Spine, Inc.Hybrid spinal plates
US8414616Sep 12, 2007Apr 9, 2013Pioneer Surgical Technology, Inc.Mounting devices for fixation devices and insertion instruments used therewith
US8574270Aug 15, 2012Nov 5, 2013Spinal Simplicity LlcBone plate assembly with bone screw retention features
US8668723Jul 19, 2011Mar 11, 2014Neurostructures, Inc.Anterior cervical plate
WO2013028951A1 *Aug 24, 2012Feb 28, 2013Synthes Usa, LlcPeek or pmma transparent implant comprising an adhesive layer of an uncured polymer.
Classifications
U.S. Classification606/294, 606/280
International ClassificationA61F2/46, A61B17/68, A61B17/70, A61F2/28, A61B17/92, A61B17/80, A61B17/00, A61F2/44, A61B17/02
Cooperative ClassificationA61B17/8042, A61B17/7059, A61B17/809, A61B17/92, A61F2002/2835, A61B2017/0256, A61B2017/00544, A61F2/4455, A61F2/4601
European ClassificationA61B17/92, A61B17/70K, A61B17/80D4
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